Engine Cooling System [Mzr 1.5]: Removal & Installation Mazda 2 II рестайлинг

ENGINE COOLANT REPLACEMENT [MZR 1.5]

Note. If the "FL22" mark is shown on or near the cooling system cap, use Mazda Genuine FL22 engine coolant. (Scheme 6): Identifying FL22 Mark On Cooling System Cap FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant. Engine coolant capacity (approx. quantity) MTX: 5.1 L {5.4 US qt, 4.5 Imp qt} ATX: 5.4 L {5.7 US qt, 4.8 Imp qt}

Scheme 5

Scheme 6

1. Remove the cooling system cap.
2. Loosen the radiator drain plug and drain the engine coolant into a container. (Scheme 7): Cooling System Cap And Radiator Drain Plug
3. Flush the cooling system with water until all traces of color are gone.
4. Let the system drain completely.
5. Tighten the radiator drain plug.
6. Referring to the following chart, select the correct volume percentage of the water and engine coolant. Antifreeze solution mixture percentage (Except FL22 type engine coolant) Engine coolant protection Volume percentage (%) Gravity at 20 °C {68 °F} Water Coolant Above -16 °C {3 °F} 65 35 1.057 Above -26 °C {-15 °F} 55 45 1.072 Above -40 °C {-40 °F} 45 55 1.086
7. Remove the battery to facilitate the removal/installation of the blind cap for air bleeding. (See «BATTERY REMOVAL/INSTALLATION [MZR 1.5]»(ref-517452-S26026055392012121200000).)
8. Remove the blind cap installed to the water pipe of the EGR valve bracket. (Scheme 8): EGR Valve Bracket And Blind Cap CAUTION: Cover the area around the blind cap with a cloth so that engine coolant leaking from the blind cap area does not get on exhaust system-related parts.
9. Refill the engine coolant to the radiator from the radiator filler neck until engine coolant begins to leak from the blind cap area.
10. Install the blind cap.
11. Install the battery. (See «BATTERY REMOVAL/INSTALLATION [MZR 1.5]»(ref-517452-S26026055392012121200000).)
12. Refill the engine coolant from the radiator filler neck until it is close to the top of the radiator filler neck.
13. Refill the engine coolant into the coolant reserve tank up to the FULL mark on the tank.
14. Install the cooling system cap. CAUTION: If the high engine coolant temperature warning light flashes, stop the engine to lower the engine coolant temperature and prevent overheating. Then, verify the malfunctioning part and repair or replace it.
15. Start the engine and warm up the engine by idling.
16. After the engine warms up, perform the following steps. At this time, be careful of the engine coolant temperature to prevent overheating. NOTE: If the accelerator pedal is depressed continuously for a certain period of time, the engine speed may decrease to the idle speed. This is because the fuel cut control operation prevents overheating, but it does not indicate a malfunction. The engine speed returns to normal control when the accelerator pedal is released. Run the engine at 2,500 rpm for 5 min. Maintain the engine speed at approx. 3,000 rpm for 5 s, and then idle. Repeat this procedure four or five times.
17. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is low, repeat steps 12-16.
18. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.5]»(ref-517443-S22797501762012121200000).)

Scheme 7

Scheme 8

1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer. CAUTION: Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur. The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to prevent corrosion and freezing. Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could damage the cooling system. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly. NOTE: If the "FL22" mark is shown on or near the cooling system cap, use Mazda Genuine FL22 engine coolant. see scheme 7: Identifying FL22 Mark On Cooling System Cap FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.
2. Determine the engine coolant protection level by referring to the graph shown in the figure. see scheme 8: Engine Coolant Protection Level Graph If the engine coolant protection level is not correct, add water or engine coolant.

COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 1.5]

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Coolant Reserve Tank And Hose With Torque Specifications. Scheme 9

Scheme 10

1. Insert the projection on the lower side of the coolant reserve tank into the insertion hole of the radiator cowling, then tighten the coolant reserve tank installation bolt. (Scheme 12): Locating Coolant Reserve Tank Bolt

RADIATOR REMOVAL/INSTALLATION [MZR 1.5]

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
3. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 1.5]»(ref-517443-S19948278132012121200000) .)
4. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 1.5]»(ref-517443-S07219285962012121200000) .)
5. Remove in the order indicated in the table.
6. Install in the reverse order of the removal.
7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.5]»(ref-517443-S22797501762012121200000) .)

Radiator And Associated Components (MZR 1.5). Scheme 11

Scheme 12

1. Remove the front bumper fitting bolt as shown in the figure. see scheme 14: Front Bumper Fitting Bolt With Torque Specifications CAUTION: To prevent damage to the upper mount rubber bracket tab, do not apply excessive force. NOTE: The upper mount rubber bracket can be easily removed by pressing down the upper mount rubber bracket tab using one hand and pressing the tab area downward using the other hand.
2. While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the figure, press the upper mount rubber bracket toward the front of the vehicle. (Scheme 14): Upper Mount Rubber Bracket Installed View
3. Remove the upper mount rubber bracket.

Radiator Removal Note

1. Remove the radiator from below the engine compartment.

THERMOSTAT REMOVAL/INSTALLATION [MZR 1.5]

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
3. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 1.5]»(ref-517441-S26221146112012121200000) .)
4. Remove the A/C compressor with hose and pipe still connected. Position the A/C compressor out of the way. (See «A/C COMPRESSOR REMOVAL/INSTALLATION»(ref-517465-S26816580292012121200000) .)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.5]»(ref-517443-S22797501762012121200000) .)

Thermostat And Associated Components (MZR 1.5) With Torque Specifications. Scheme 13

Scheme 14

1. Install the thermostat with the jiggle-pin at the top. see scheme 17: Identifying Thermostat With Jiggle-Pin

WATER PUMP REMOVAL/INSTALLATION [MZR 1.5]

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
3. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 1.5]»(ref-517441-S26221146112012121200000) .)
4. Remove the generator. (See «GENERATOR REMOVAL/INSTALLATION [MZR 1.5]»(ref-517452-S17671143142012121200000) .)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.5]»(ref-517443-S22797501762012121200000) .)

Water Pump And O-Ring With Torque Specifications. Scheme 15

O-ring Installation Note

1. Apply engine coolant to a new O-ring.
2. Install the O-ring.

COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 1.5]

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
3. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 1.5]»(ref-517443-S19948278132012121200000) .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 1.5]»(ref-517443-S15590813912012121200000) .)
7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.5]»(ref-517443-S22797501762012121200000) .)

Cooling Fan Motor And Components (MZR 1.5) With Torque Specifications. Scheme 16

1. Release the left and right tabs on the upper side of the radiator by pressing them in the direction shown in the figure. (Scheme 17): Left Tab On Upper Side Of Radiator
2. Lift the cooling fan component to remove it from the left and right insertion areas on the lower side of the radiator. see scheme 21: Left Insertion Area On Lower Side Of Radiator
3. Remove the cooling fan component from below the engine compartment.

Cooling Fan Component Installation Note

1. Insert the cooling fan component in the left and right insertion areas on the lower side of the radiator, and then attach the left and right tabs on the upper side of the radiator.

Scheme 17

1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [MZR 1.5]»(ref-517452-S26385973642012121200000).)
2. Disconnect the cooling fan motor connector (4 terminals).
3. Install a tester and battery to the cooling fan motor connector (4 terminals) as shown in the figure. see scheme 22: Identifying Cooling Fan Motor Connector Terminals
4. Verify that the fan motor operates smoothly at the standard current. If there is any malfunction, replace the applicable part. Cooling fan motor standard current [12 V] 7.4-11.4 A